Owens Corning Kansas City plant - Executive Summary
EXECUTIVE SUMMARY |
Owens Corning is committed to achieving environmental leadership
within its industry and beyond. The Insulation Systems Business Unit
(ISB), of which the Kansas City Insulation Plant is a key part,
demonstrates this pursuit of excellence by proactively managing its
operations to reduce environmental impacts while improving the quality
of its products and the well-being of its employees and the community.
ISB Environmental has implemented a programmatic approach to
compliance with the EPA's Risk Management Program (RMP) Rule. All of
the business unit's manufacturing facilities will address process safety and
risk management issues for key materials utilized by the plants in
manufacturing fiberglass insulation products. The program will fulfill the
general duty clause requirement in the RMP rule. Facilities, like Kansas
City, with threshold quantities above the RMP triggers, have utilized a
management manual system to comply with the
requirements of RMP.
This submittal only characterizes the subject processes that require a RMP
submittal and certification by June 21, 1999.
The Kansas City plant holds Environmental Stewardship, along with
Safety, Productivity, and Quality, as one of its (4) driving principles.
Located in the Fairfax Industrial District for 52 years, the Kansas City
plant is an integral part of the Kansas City, Kansas community.
Membership in such organizations as Friends of Fairfax and the
Wyandotte County Coalition for Chemical Safety emphasize the
importance with which the plant views their commitment.
2.0 ACCIDENTAL RELEASE PREVENTION AND EMERGENCY RESPONSE
Owens Corning is committed to developing and operating its
manufacturing facilities in a manner protective of the environment and
human health. This priority is expressed through continuing process
improvement, risk reduction, and an emphasis on pollution prevention.
In order to produce the quality products that Ow
ens Corning is known
for, the Kansas City facility uses a 50% formaldehyde solution in the
manufacturing of fiberglass binder resin for use at the facility. Because
this is a toxic chemical, numerous controls have been implemented to
prevent an accidental release of this chemical. In the event of a release, the
Kansas City facility has an emergency response program that will be
implemented. This program is made up of hourly and management
employees who have been properly trained in certain elements of
emergency response, as well as communication with the appropriate
responder organizations in the community.
3.0 DESCRIPTION OF THE FACILITY AND REGULATED PROCESSES
The Kansas City facility, located at 300 Sunshine Road in Kansas City,
Kansas, is a producer of wool glass fibers, which are fabricated into
insulation materials. Glass fiber manufacturing involves the high-
temperature conversion of various materials into a homogeneous melt,
followed by the fabrication of thi
s melt into glass fibers. After the
formation of the glass fibers, a thermosetting chemical binder solution is
applied to the fibers. The glass fibers and binder solution are then
collected on a conveyor belt where they are sent through a large curing
oven and then through a cooling section. The result is a mat that is then
cut into batts or rolls of the desired dimensions and then packaged.
Kansas City Insulation plant has a single covered process that is subject to
RMP. The 50% formaldehyde solution that is utilized in a process to
manufacture the binder resin is a Program Level 3 process. The
formaldehyde resin is a binder system ingredient used to manufacture
wool fiberglass insulation at the plant.
4.0 HAZARD ASSESSMENT RESULTS
Owens Corning has determined the distance to the toxic endpoints for the
regulated substance present at the Kansas City facility. The following
release scenarios have been considered:
Aqueous formaldehyde is stored in
storage tanks. The tanks are located in a diked
containment area. Trucks unload the material
through a 3-inch hose. All truck unloading takes
place in a separate containment area designed for that
purpose. Both the storage tanks and the truck are
maintained at 150? F.
Worst-case release is an instantaneous release of the
maximum inventory of one tank, which forms a
liquid pool in the dike. The release duration is
assumed to be 60-minutes because the concentration
of formaldehyde in solution after 10-minutes of
evaporation is not significantly lower than the initial
Distance to Endpoint - 0.456 miles (ALOHA)
The alternative release involves a failure of the
unloading hose during product delivery resulting in a
release of 500 gallons over a 5-minute period. The
liquid released from the line/hose break is contained
in the truck unloading area.
Distance to Endpoint - 0.116 miles (ALOHA)
The release scenarios examine
d above could result in off-site impact. Both
OCA guidance look-up table values and air dispersion modeling results
for the toxic compounds via ALOHA were examined and reported as
5.0 GENERAL ACCIDENTAL RELEASE PREVENTION/CHEMICAL-
SPECIFIC PREVENTION STEPS
Mitigation measures were considered in formulating the alternative
scenarios since unloading incidents are the most commonly occurring
Accidental releases are mitigated by an aggressive spill reporting program
and operator and Emergency Response Team training in spill response.
6.0 FIVE-YEAR ACCIDENT HISTORY
No documented off-site impacting accidents have occurred within the last
7.0 EMERGENCY RESPONSE PROGRAM
Kansas City maintains an up-to-date Emergency Response Plan and
conducts annual drills to train on response procedures. In addition, the
Kansas City plant maintains an Emergency Response Team on all shifts.
The Emergency Response Team is trained in personal rescue, fir
st aid, and
response to chemical release.
8.0 PLANNED CHANGES TO IMPROVE SAFETY
The following list of capital improvements represents an investment of
approximately $100,000 made during the last two years in upgraded
process safety controls and other equipment to mitigate and reduce the
prospect of an accidental release.
Formaldehyde Storage Tanks - Barrier Wall
Redesign of Formaldehyde Scrubber
Pipe Bridge spill containment - Tank Farm to Binder Room
Pipe Bridge spill containment - Phenol unloading to Reactor Building
Pipe Bridge spill containment - Tank Farm to Reactor Building
Ultrasonic probe level monitors installed - Formaldehyde and Phenol
Freeze protection enclosures around critical unloading and transfer
Grounding of tanks
Replaced much hot water heat tracing with electric
New surface on reactor containment area
Modified resin recirculation loop, and added double-sealed pump
In 1998, the plant received approval for a three-year extensive pr
for upgrade of facilities associated with the chemical processes
surrounding resin manufacture and binder mixing (of which some of the
above-mentioned projects are a part). This program, aimed primarily at
release prevention and automation of certain manual processes, will
further reduce likelihood of accidental chemical releases. The total value
of this capital investment is $924,000